Plastic composition product and method of producing articles of manufacture



hXmlHtH l Y* m.. i in y .May 3,1921, 1.627.296

A. J. lSLQSSER PLASTIC COMPQSITION PRODUCT AND VMETHOD OF f `PRODUCING RTICLBS IANUFACTURE Filed Avril .,1926

t/glgef 1,0388!" by Patented May 3, 1927.

UNITED STATES PATENT OFFICE.

ALGER J'. SLOSSER, OF WILLIAISPOBT, PENNSYLVAN'IA, ASSIGNOR TO POHPEIAN FLOORING COMPANY, `OF WTLLIAMSPORL PENNSYLVANIA, A CORPORATION OF PENNSYLVANIA.

PLASTIC COMPOSITION PRODUCT AND METHOD OF PBODUCING ARTICLES 0I' IIANUFACTURE.

Application led April 20,

This invention relatesto plastic compositions and more particularly to composition products for the production of flooring and various articles o manufacture. It aims to provide an im roved composition product and method o working the same .in the production of flooring and other articles of novel character and appearance.

One of the objects is to rovide a fibroid com osition that may readily be worked or fashioned into the finished roduct which will be characterized by resilient qualities as distinguished from the hard and inflexible products of the ordinary mineral conipositions for artificial stone and which will nevertheless possess the necessary enduring and wearing qualities.

Another object is to provide a composition and method of producing flooring and other articles of manufacture, permitting a wide range of variation in form, design and coloring of finished products.

A further object is to provide a composition which when set and hardened2 may be scraped and polished in a manner similar to that in which wood fiooring is ordinarily treated.

Inexpensc in the cost of production and the attainment of attractive effects in apr pearance of the finished products are still further desiderata which have been borne in mind in the perfection of my composition and method of forming or producing different' articles of manufacture.

The invention will be hereinafter more particularly described with reference to the accompanying drawings and the practice thereof in the production of composition flooring, although it will be understood that the invention is applicable to other uses and the production of variousrother articles of manufacture.

In said drawings:

Fig. 1 is a re resentation of a body or slab composed o a composition embodying this invention and presenting a surface of spotted or mottled appearance;

Fig. 2 is a representation of a section through the body or slab shown in Fig. l;

. Fig. 3 is a representation of a similarly formed body or slab presenting a mottled surface of different appearance produced by 192s. semina. masso.

fibrous concretions of larger size and the use of a coloring matter;

Fig. 4 is a representation of a section through the body or slab shown in Fig. 3;

Fig. 5 is a representation of another similarly formed body or slab in which a mottled surface of more compact appearance is produced;

Fig. 6 -is a representation of a section through the body or slab illustrated in Fig. 5; v

ig. 7 is a representation of still another similarly formed body or slab presenting a mottled surface of appearance differing from the former illustrations and produced bydthe use of contrasting coloring matters; an

Fig. 8 is a representation of a section through the body of the material shown in Fig. 7.

My improved composition embodies different ingredients or materials mixed togather in different proportions to provide a plastic or tactile mass. A vegetable ibrous material, such for instance as E200-@1h12 or wood-flour, is employed as the asie or principal ingredient of the composition and is mixed with the other ingredients thereof in such proportions as to provide a formative mixture or mass of relativel high fibre content. With the aforesaid brous ingredient or material, a mineral brous m aterial such as fibred asbestos is combined, together with a binding agent or cementing material such for instance as caustic calcined magnesia of a grade equal to that used in magnesite stucco. The binding liquid which is late radded to the dry materials of the coniposition; may be a solution of magnesium chloride.

l In the practice of the invention, a practicable mixture or mix as it is called, which will produce desirable and very eli'ective. results, may be obtained from the following formula in which the several ingred ients are givei in approximate proportions by weight as follows: 45% caustic calcined mavnesia, 30% 'Whimmnun 2o' 70 asbestos lum s or oa s.

The dry ingredients or materials,in proportions substantially in accordance with the above exemplary formula, are first placed "Examiner together in a suitable container where initially they are thoroughly mixed in a dry state. To this dry mixture, a proper amount of the binder liquid, which in this instance is magnesium chloride preferably at a gravity of 22 Baume q. s., is slowly added in proper proportion to produce a plast1c mixture or mass in which cgncretlons or lumps of the fibrous material are sustained. As the binder liquid is added, a chemical action takes place, causing the components of the previously dry mix to bind or come together and www or lumps of the rous materla the binder solution being added slowly and a mixing being simultaneously 'carried on until a plastic mixture or mass composed almost entirely of these soft fibrous concretions or lumps is attained. The materials which are'thus taken u by or in effect congealed and supported 1n the bint in liquid when the latter is dded` are en gen y stirre or agitated until a thorough mixture and equal distribution of the fioating lumps is attained throughout the plastlc mass.

When working to produce a mottled effect in the surface of the resulting product, care should be taken not to make the mixture too wet as its consistency should be such that the resultiner mass will be of a th'ck lastic charactebr and not in the formPLoIl'iqiii-d pulp. The lumps or balls of fibrous material which are thus equally distributed throughout the s ortinfT li uid binder, may and will vary in size and 1n consequence will tend to vary th size of the mottling effect roduced in thelihed floor or article un er formation when he prepared composition is spread out or dumped into a mould. v

In practicing the invention in the 'production of flooring, either over a relatively large area or in the form of flooring tiles. the prepared mixture or plastic mass of fibrous materials is dumped` outl and spread to the desired thickness over the surface to be covered, the latter having been properly prepared for the purpose. The spreading may be aided by the use of a trowel or other tool.

After being spread out over the surface with fairly uniform thickness, the plastic mass is then tamped or rolled by suitable means so that .the sustained concretions or lumps of fibrous materials will be closely compacted to provide a smooth slab or flooring surface o the proper density. Should incompletely covered spots or depressions appear in the surface of the newly spread floorinfr after the tamping or rolling operation, they may be covered or filled up by the spreading of additional material thereover, after which the tampin or rolling operation should be repeate until the proper level and a smooth unbroken surface is obtained.

The newly spread surface is then carefully gone over with a steel trowel or other tool similarly to the manner of laying cement so that the surface may be smoothed out still further. After this operation, the nen-ly spread surface should be allowed to stand and settle until it attains a set sufficiently hard to permit a workman to walk upon it without leaving marks in the surface thereof. The length of time required for the spread mass to set and attain the proper hardness will vary somewhat according to the surrounding atmospheric conditions, although rdinarily it would require only about eight hours.

After the Hoor or surface has set to the propler hadnessit may bt treated with a mec anica scra infr or san ing machine. or hand scraper'sifFaSkfiii/d ordinarily used on hardwood flooring may be used to scrape and /smoofh ofi' the'surface. S 1 1c l 1 a scrap ing OY Sanding OPGFHOIJJELexpQse..a news tli-e'des'ign or character of the mottllng being dependent upon and varied according to the size of the concretions or lumps of fibrous material and the coloring matter used in the composition.

Several of the many different forms or effects of mottling which may be attained 1n the practice of the invention have been represented in the drawings. the mottled designs or effects being variable according.r to the proportions of the ingredients used, the extent or thoroughness with Which the fibrous materials are stirred and broken up and the coloring matters employed in the composition.

In the practice of the invention according to the method above set forth, a color or tint may be given to the finished product by the use of coloring matter in the mixture of the composition and either a blending or contrasting combination of colors in V(the mottling of the product may be attained by preparing the composition with intermixed concretions or lumps of fibrous material of different colors in the manner' hereinafter set forth.

Then coloring matter is to be used in the composition, the dry ingredients thereof in Variable proportions according to the exemplary formula given above, are first placed together in a container and mixed as liereinbefore described. The desired coloring matter, preferably in the form of a dry coloring pigment, is added and mixed with the dry ingredients before the binder liquid is added thereto. Coloring pigments may be added in proportions from five to twenty per centof the wei ht of the drv mixture depending upon t e grade and quality of the pigment and the depth of Sli tlf)

colorin desired in the finished product.

v After At e coloring pigment has been thoroughly mixed with the dry ingredients. the binder liquid is vadded and the combined materials are then further mixed -to attain an even distribution of fibrous materials and coloTiig matter, after which the plastic composition may be Worked or moulded into the desired form.

When Working to produce a composition and mottled product embodying a combination of contrasting colors, a separate complete miXt-ure or mass for each of the colors to be included would be prepared in the manner just described. The separately prepared mixtures of different colors are then placed together in' a single large container and gently stirred or mixed together to effect an even distribution of the'difi'crently colored fibrous concretions or lumps throughout the body of the final mixture. Care should be taken in thus intermixing the consolidated separately prepared mixtures as a too vigorous agitation thereof may cause the differently colored fibrous concretions or lumps to break up or disintegrate, alloiving their colors to run together and bl e i 1l. However. if a blending of the different colors is desired. the consolidated mixtures may and should be agitated vigorously for the purpose of breaking up the fibrous lumps. allowing their colors to run together and 'f blend.

After the separately prepared mixtures have been consolidated and intermixed, producing the final plastic composition or formative mass, the same may be spread overl a flooring surface or moulded and worked into the form desired. In either case, the surface treatment after the composition has set and hardened may be substantially the same as that hereiubefore dehardwood fiooring.

Another novel and unique effect may be roduced from a colored mixture or a commation of tivo or more differently colored mixtures by sifting a contrasting.r coloring dry pigment thereover in such quantities that after a careful mixing without break- -ing up the individual concretions or lumps of fibrous materials. each of the concretions or lumps thereof will become thinly coated with said contrasting color. After the composition has been spread ont. or moulded lnto form and left to harden and then scraped to expose a Wtic mass composed almost entirely of soft tion merely by varying the consistency of the mixture so that the concretions or lumps of fibrous materials Will be broken up.l as a /result of vvhich the finished product will present a smooth surface of unmottled rather than mottled appearance.

Since the composition contans a relatively high percentage of fibrous material, it may be used in the making of various articles of manufacture, either in or upon a mould there mechanical pressure may advantagcously be applied, or by initial formation in a solid body ivlch upon setting and hardening ma)v be turned en a lathe to produce the finished article after theV manner of the Wood-Working art. lts use is not therefore limited to the production of flooring or the formation of fiat surfaced articles.

Furthern'xore, variations in the relatlve quantities or proportions of the different ingredients embodying the composition may be made in the mixture thereof for the purpose of attaining different effects in the finished products Without departing from the spirit and scope of this invention and I therefore do not limit myself to the specific proportions of the ingredients as given in the formula hereinbefore set forth.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent of the United States is:

1. A composition product consisting of a vegetable fibrous material, a mineral fibrous material, a dry cementing material and a liquid binder solution mlxed together in proportions producing a plastic mass composed almost entirely of soft concretions or lumps of the fibrous materials held together by the binding materials substantially as described.

2. An improved productA or article of manufacture, consisting of a mixture of a. Woodtibre or Wood-flour with proportions of asbestos fibre and caustic calcined magnesia, to which a. liquid binder solution of magnesium chloride is added slowly, in sufiicient quantity to produce a plastic mass composed of soft floating concretions or lumps of the fibrous materials substantially as described.

3. An improved product or article of manufacture, consisting of a. mixture of a vegetable fibrous material with asbestos ires and caustic calcined magnesia in relative proportions of a proximately forty-five, thirty and twenty-tive per cent by weight respectively of the mixture and a liquid binder solution of magnesium chloride added thereto in sufficient proportion to produce a plasconcretions or lumps of the fibrous materials which maiv be worked or moulded into the desired form. substantially as described.

4. The herein described method of producing a composition flooring.1r or other article of manufacture. characterized b v mixing together a vegetable fibrous material, bred asbestos and caustic calcined magnesia in relative proportions of approxi-` matel)v 45, 30 and 25 per cent by weight respectivelyv of the mixture and adding i slowls` thereto a liquid binder solution of magnesium chloride in sutiicient quantity to produce a plastic mass composed almost entirely of sott concretions or lumps of the fibrous materials, spreading or moulding the mass int-o the desired form. allowin': the same to set and harden and then treatingY the surface thereof. substantialv as described.

5. A method of producing: a composition flooring or other article of manufacture having a mottled surface appearance. characterized b v mixinLr together a vegetable fibrous material, tibred asbestos and caustic calcined magtnesia in relative proportions of 45. 30 and 25 .per cent bv weight respectively of the mixture. adding: to such mixture. a liquid binder solution ot' magnesium chloride in sutlicient quantity to produce a plastic mass composed of soft concretions or lumps of the fibrous materials with said ibrous concretions or lumps evenly distribute'd therein, spreading lor moulding the plastic mass into the the from desired, allowing the same to set and harden and then scraping or sanding the surface thereof to expose a new surface in which the fibrous concretions will resultinglv appear in mott-ling effect.

k6. The hereinvdescribed method of producing a composition flooring or other article of manufacture which consists in mixing together relative proportions of Woodfibre or wood-flour, bred asbestos and caustic calcined magnesia and adding slowlyr thereto a liquid binder solution of magnesium chloride in sufticient quantity to produce a plastic mass composed almost entirely of sott concretions or lumps of the fibrous materials held together by the binding materials. spreading or moulding the mass into the desired form. allowing the same to set and harden and then scraping or sanding the surface thereof to .expose a new sur ace substantially as described.

In testimony whereof I affix my signature.

ALGER J. SLOSSER.

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